Oil Pan

Fig. Fig. 2: A long extension will be necessary to remove some oil pan bolts

Fig. Fig. 3: Lifting the oil pan down from the engine block

Fig. Fig. 4: Notice that on this 1992 GA16DE the support member and exhaust where removed for easier access

Fig. Fig. 5: All of the old gasket must be scraped away before installing the new gasket

Fig. Fig. 6: Using a seal cutter on the oil pan

Fig. Fig. 7: Apply RTV sealer on the inside of the bolt holes

Fig. Fig. 8: Apply an even bead of liquid or RTV sealer around the oil pan. Let the RTV set until a thin skin appears, then install-E16i engine shown

CAUTION

The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

1982-88 E-Series and Diesel Engines

If the engine is in the vehicle, attach a lift, support the engine, and remove the engine mounting bolts.

Raise the engine slightly, watching to make sure that no hoses or wires are damaged.

Drain the engine oil.

Remove the oil pan bolts and slide the pan out to the rear.

Remove any old gasket material which remains on the pan and/or block.

To install:

Use a new gasket, coated on both sides with sealer.

Apply a thin bead of silicone seal to the engine block at the junction of the block and front cover, and the junction of the block and rear main bearing cap. Then apply a thin coat of silicone seal to the new oil pan gasket, install the gasket to the block and install the pan.

Tighten the pan bolts in a circular pattern from the center to the ends, to 48-84 inch lbs. (6-10 Nm). Overtightening will distort the pan lip, causing leakage.

Reinstall the engine mounting bolts.

Refill the oil pan to the specified level.

1987-90 CA16DE, CA18DE and GA16i Engines

Drain the engine oil.

Raise the vehicle and support it with safety stands.

Remove the right side splash cover. Remove the right side under cover.

Remove the center member.

Remove the forward section of the exhaust pipe.

Remove the front buffer rod and its bracket.

Remove the engine gussets.

Insert a seal cutter (SST KV10111100) between the oil pan and the cylinder block.

DO NOT use a screwdriver!

Tapping the cutter with a hammer, slide it around the oil pan.

Remove the oil pan.

To install:

Remove all gasket material from the pan and block mating surfaces.

Apply a continuous bead (3.5-4.5mm) of RTV gasket material around the oil pan. Apply the sealer to the inner surface around the bolt holes where there is no groove.

Install the pan within 5 minutes. Do not allow the sealer to dry. Tighten the pan bolts in a circular pattern from the center to the ends, to 48-84 inch lbs. (6-10 Nm). Overtightening will distort the pan lip, causing leakage.

Refill the oil pan to the specified level. Start engine and check for oil leaks.

1991-96 GA16DE Engine

Disconnect the negative battery cable.

Raise and safely support the vehicle.

Remove the under covers.

Remove the oil pan plug and drain the oil into a container.

Remove the front exhaust tube.

Remove center crossmember assembly.

Remove the support brackets from the sides of the oil pan.

Remove the oil pan mounting bolts. Using the oil pan seal cutter tool KV10111100 or equivalent, separate the oil pan from the engine.

WARNING

Do not drive the seal cutter into the oil pump or rear oil seal retainer portion, for the aluminum mating surfaces will be damaged. Do not use a prybar to remove the oil pan; the flange will be deformed.

Remove the right side splash cover. Remove the right side under cover.

Remove the lower oil pan bolts and separate the pan using tool KV10111100.

Remove the baffle plate and front tube.

Place a transmission jack under the transaxle and raise.

Remove the center member and automatic transaxle shift control cable.

Remove the compressor gussets.

Remove the rear cover plate and aluminum oil pan bolts.

Remove the 2 engine-to-transaxle bolts and install them into the vacant holes. Tighten the bolts to release the oil pan from the cylinder block. The oil pan removing tool KV10111100 or equivalent, may have to be used to release the pan from the block.

To install:

Remove all old gasket material from the pan and block mating surfaces.

Apply a continuous bead (3.5-4.5mm) of RTV gasket material around the oil pan. Apply the sealer to the inner surface around the bolt holes where there is no groove.

Install the pan within 5 minutes. Tighten the pan bolts in a circular pattern from the center to the ends, to 48-84 inch lbs. (6-8 Nm). Overtightening will distort the pan lip, causing leakage.